>) TOYOTA REPAIR MANUAL Aug., 1999« FOREWORD This repair manual has been prepared to provide information covering general service repairs for’ ‘TE engine equipped on the TOYOTA HILUX. Applicable models: KZN165 series Please note that the publications below have also been prepared as relevant service manuals for the compo- nents and system in this engine. Manual Name Pop. No- EwOo07F ILUX Electrical Wiring Diagram All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION musts @1999 TOYOTA MOTOR CORPORATION Allrights reserved. This book may not be repro- duced or copied, in whole or in part, without the ‘written permission of Toyota Motor Corporation. Elret Parting’ lin 171. 199901-900R1400-24 LSE Tw PREPARA DI ENGINE MECHANICAL [fay TURBOCHARGER [fixe EMISSION CONTROL IZ [ELECTRONIC CONTROL DIESEL [ay [ENGINE FUEL [i (COOLING Kee [LUBRICATION 1 STARTING CHARGING ALPHABETICAL INDEX [ty* INTRODUCTION rel *€ Pe (IDENTIFICATION INFORMATION 2... _IN-3] FOR ALL OF VEHICLES . ve IN PRECAUTION ... IN-8 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS . IND No GENERAL INFORMATION... ....--- HOW TO PROCEED ’ |_WITH TROUBLESHOOTING ........1.1..1. —IN=10] [HOW TO USE THE DIAGNOSTIC CHARTINTROUUETION ~ _ HOWTTOTOSETTHIs MANUAL’ HOW TO USE THIS MANUAL _ GENERAL INFORMATION odT + 1. INDEX . wwe wn . ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN-9. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operation and explains the purpose ofeachone. + 5. REPAIR PROCEDURES Mest repair operations begin with an overview illustration. parts fit together. ses so Example: - 3 . identifies the components and shows how the z Driven Rotor + 9ngq ort navin 618 uoy beriuper 9x8 veri! nadw aso. ated as, onatgte avorrag” 2 aveal of eved 1ev80 voY hebean & Ai bain. : tos, yprol noweee @ 0h 29 u oer. 26 eon @ Crankshaft Front Oil Seal ‘ 2 m™ bons 8 TURD 910083 amor balnszang cals 16 27" TOK ‘squt ytisd ae donne no OTE MONE oe. 918 OTH 18 quay qiert &—— rele Valve HEED gee eR getsmntaly THA 12 rat sheasees he aig ae Ieee ait alnevir vt ar s Spr wy pring ica ater. 5 bi e—— @ Gasket alee motpy OFE) m4 OE 292 & fina m (kgFom, f) | : Specified torque Bore, ‘# Non-reusable partIN-2 INTRODUCTION — HOWTO USE THIS MANUAL The procedures are presented in a step-by-step format: + The illustration shows what to do amd where to do it. + The task heading tells what to do. mes — + The detailed text tells how to perform the task and gives other information such as specifications andwamings. 5. oye “Task headiig what iodo 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (@) Place SST and a dial indicator onto the overdrive brake pis- * ton as shown in the illustration, SST 08350-20020, (09050-06120) a a3 Set part No. CBmponent partNo. : Detailed text: “how todo task " (0) Measure the stroke applying and releasing the compressed air (392 — 785 kPa, 4—8 kgl/cm? or 57 — 114 psi) as shown, in the ilustration. _ Piston stroke: 1.40 — 1.70 mm (0.0861 — 0.0669 in) This format provides the experienced technician wih a FAST TRACK tothe information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed informa tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Spectcations are presented In bold type throughout ihe text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: te wae f + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other } people. 1 + NOTICES are also presented in bold type, and indicate the possibilty of damage to the components | _ being repaired. + HINTS are separated from the text but do not appear in bold. They frovide additional information td help you perform the repair efficiently. , i 9. SIUNIT ‘The UNITS given in this manual are primarily expressed according to the S! UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N-m (310 kat-cm, 22 ft-bf) | | a |IN-3 INTRODUCTION — IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration.Ina IWTROOUCTION —_ REPAIR INSTRUCTIONS @ (b) (0) (e) @ (9) REPAIR INSTRUCTIONS GENERAL INFORMATION Pt BASIC REPAIR HINT lan Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following operations: (1) Before performing electrical work, disconnect the negative (-) terminal cable trom the battery. (2) it is necessary to disconnect the battery for in- spection or repair, always disconnect the negative (G) terminal cable which is grounded to the vehicle body. (8) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth- er abrasive objects. (5) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the °@" symbol. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) Ia precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. (3) Precoated parts are indicated in the component il- lustrations by the **” symbol. When necessary, use a sealer on gaskets to prevent leaks.INS <5 -WETRODUCTION —_REPAIS INSTRUCTIONS, . th) c @ = a an 2 er wiph anor Medium Current Fuse and High Current Fuse Equal Amperage Rating Carefully observe all specifications for bolt tightening torques. Always use a torque wrench, Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where speci- fied and follow the proper work procedure. A list of SST and SSM can be found in section PP (Preparation) in this manual. When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use one with a lower rating a FUSE FUSE Fo MEDIUM CURRENT FUSE ee HIGH CURRENT FUSE es) cmunw ‘| aa, | rubiete Link SFL | peeve a . eae Gr # pst CIRCUIT BREAKER cay sess ose : “oteni yo evn—==y of donstw wer enmeto yet oi tees # ory OK, ‘s2orf sdf sro! revert .2QUBD MWL2BV & swob- Bee sow ad mw % isa ym fi @ | w oe ‘Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations. + Cancel the parking brake on the level place and 9 shift the transmission in Neutral (or N position). + When jacking up the front wheels of the vehicle at tz first place stoppers behind the rear wheels. + When jacking up the rear wheels of the vehicle at first place stoppers behind the rear wheels.INTRODUCTION —_REPARNETRUCTIONS _ + When either the front or rear wheels only should be “jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground. + After the vehicle is jacked up, be sure to support i oege (on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for ‘a small job that can be finished quickly. () Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless aerators anes seid pon pine! absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electnic- ity.) - (2) Todisconnect vacuum hoses, pull off the end, not WRONG .__ CORRECT __ 4 the middle of the hose. — (3) Topull apart electrical connectors, pull on the con- nector itself, not the wires. (4) Be careful not to drop electrical components, such 7 as sensors or relays. If they are dropped on a hard fioor, they should be replaced and not reused. , (6) When steam cleaning an engine, protect the elec - tronic components, air filter and emission-related components from water. (6) Never use an impact wrench to remove or install temperature switches or temperature sensors. ait - ee s©' (7) When checking continuity at the wire connector, in a rc sert the tester probe carefully to prevent terminals from bending. leval ant ne averd neissen ert (8) When using a vacuum gauge, never force the hose v 7H = 7 at onto a connector that is too large. Use a step-down 46 80. : * adapter for adjustment. Once the hose has been a stretched, it may leak. tw st antt bailed, aIN-7 INTRODUCTION —_ REPAIR INSTRUCTIONS (ny (m)_ Tag hoses before disconnecting them: (17 When disconnecting vacuum hoses, use tags to identity how they should be reconnected. « « (2) After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resis- tance may be outside specifications if measured at high temperatures immediately after the vehicle has been run- ning, measurement should be made when the engine has cooled down.IN-8 INTRODUCTION FOR ALL OF VEHICLE: FOR ALL OF VEHICLES PRECAUTION 1 IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. 2 (1) _ Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve- hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with the other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (6) Do not install powerful mobile communications system, FOR USING HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: Betore using the hand-held tester, the hand-held tester’s operator manual should be read throughly. Be sure to route all cables sectifely wheri driving with the hand-held tester connected to the vehicle. (le. Keep cables away from feet, pedals, steering wheel and shift le ‘Two persons are required when test driving with the hand-held tester, one person to drive the vehicle and one person to operate the hand-held tester.a INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED me SYST HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION Alarge number of ECU controlled systems are used in the HILUX. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: Sysiem Page Engine Dit ‘The troubleshooting procedure and how to make use of it are described on the above pages. FOR USING HAND-HELD TESTER + Before using the hand-held tester, the hand held-tester’s operator manual should be read throughly. «Ifthe hand-heid tester cannot communicate with ECU controlled systems when you have connected the cable of the hand-held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) _ If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus@line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outlined in the Tester Operator's Manual.IN-10 INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in each section, showing the most effective methods for each circuit. ‘Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. au ‘Vehicle Brought to Workshop) U 1 1 Customer Problem ‘Ask the customer about the conditions and the Analysis > environment when the problem occurred. u ; » 2 + [Symptom Confirmation 3 : Gcee Goose? ‘| 1 Code Check Siren a 2,3 2 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. . (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) . 4 Diagnostic Trouble Code Chart = Problem Symptoms Table, 4,56 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic 6 /Crouit ingpeation or Paris trouble code chart or the problem symptoms table. Inspection 7 ‘Check and repair the affected system or part in accordance with the instructions in Step 6. 7 [ Repai 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) Confirmation Test aINTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED Laid SYSTEMS 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must BS confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis. © What Vehicle model, system name © When —— Date, time, occurrence frequency @ Where Road conditions © Under what conditions? ‘© How did it happen? ogra, = me Running conditions, driving conditions, weather conditions Problem symptoms ‘ at en we 5 ott ot (sample) Engine control system check sheet. 09 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet} jrspectors Modol and Modo Year Frame No. Engine Mode! ‘Odometer Reading Taengine does | T Engine does not crank {No ntl combustion No complete combustion TDoimourte | Engine oranke slowly Sut Bother Dincorrect fest idle Cliating rpm is abnormal — CO High( pm) Low ( GRoughiding other Poor iating Poor DHesitation Back fire D Muttior explosion (after—fire) Osurging Drive ability | Knocking __ Ci Other. Doon efter starting CD After accelerator pedal depressed Gengine Stalt | C1 After accelerator pedal released C1 During A/C operation Cishitting trom N to D other Problem Symptoms Sometimes ( times per —_day/montue e INTRODUCTION - HOW 70 TROUBLESHOOT ECU CONTROLLED SysTeMs, 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK a The diagnostic system in the HILUX fulfils varios functions. The first function is the Diagnostic Trouble Code Check in which a matfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. i By using these check functions, the problem areas can be narrowed down quickly and troubleshooting caf be performed effectively. Diagnostic functions are incorporated in the following systems in the HILUX. Diagnostic Trouble | Input Signal Check | Other Diagnosis ‘Sysien Code Ghack | (Sensor Check) Function Engine © ° Diagnostic Test {with Test Mode) Mode In diagnostic trouble code check, itis very important to determine whether the problem indicated by the diag- nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom ot not. For this reason, the diagnostic trouble codes shouid be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROGEDURE eae ee eee Confirmation | Diagnostic Trouble) Problem Condition jagnostic Trouble Code Check (Make a note of and then clear)| Of S¥mptoms | Cede Check Diagnostic Trouble Problem symptoms] Same diagnostic | Problem is still occurring in the diagnostic Code Display ~_Jexist trouble code is | circuit displayed 1 ons Normalcodeis | The problem is stil occurring in a place — —— = saispiayed other than in the diagnostic circuit } (The ciagnostic trouble code displayed! first is either for a past problem or itis al secondary problem) cite | problem The problem occurred in the diagnostic Symptoms exist z circuit in the past i Normal Code Display,_[Problem symptoms| Normal code is__| The problem is still occurring in a place xist = | displayed Jother than in the diagnostic circuit _ jo problem Normal codeis | The problem occurred in a place other] | . S7Symptoms exist | displayed {than in the diagnostic circuit in the past. W INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED we13 SYSTEMS Taking into account the above points, a flow chart showing how ta proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms. « i Diagnostic trouble code check - ide 5 ab : Making a note of and clearing ofthe diagnostic trouble codes displayed at mye maleiorg sn tc bammitnoa sd setuc ‘Symptom confirmation ar woe Problem symptoms] | No problem symptoms exist a o ‘Simulation test using the symptom pannel ‘simulation methods Sete eee Eee a 7 ic Diagnostic trouble code check 4 ‘* Diagnostic trouble code displayed | [© Normal code displayed ‘© Normal code displayed ‘* Problem symptoms exist Problem symptoms exist © No problem symptoms exist | | Troubleshooting of problem indicated Troubleshooting of each { System Normal “by diagnostic trouble code problem symptom If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates i Ash that the trouble may have occurred ' in a wire hamess or connector in ere ae that circuit in the past. Therefore, check the wire harness and con- —————L——_|_nectors (See page IN-20}.. e kde UGIN-18 INTRODUCTION — HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 3. SYMPTOM SIMULATION “The most dificult case in troubleshooting is whershere are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem ‘symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en- Qine is cold, or for a problem which occurs dus to vibration caused by the road during driving, etc., the prob- lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex: ternal causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out, To do this, narrow down the possible problem circuits according to the symp: toms before starting this test and connect a tester beforehand, After that, carry out the symptom simulation test, judging whether the cir ing tested is defective or normal and also confirming the problem symp- toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 | VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. 909 . - WIRE HARNESS: Slightly shake the wire harness vertically and horizontally. fer The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thorough- ly. win iat PARTS AND SENSOR Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINTE: Applying strong vibration to relays may result in open relays.ena a ~—_ INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. at the component that is the likely cause of the malfunction “ra hairdryer or similar object. Check to see if the malfunction 18. ‘once: *) Do not heat to more than 60°C (140°F). (Temperature is limited not to damage the components.) 2) Do not apply heat directly to parts in the ECU. \ eeaaeae frase IN-15 4% ., When the malfunction seems to occur on a rainy day or in a WATER SPRINKLING METHOD: Hai ation, ‘Sorinkle water onto the vehicle and check to see if the maifune- 2 occurs. NOTICE: (1) Never sprinkle water directly into the engine ‘compartment, but indirectly change the temperature and| humidity by applying water spray onto the r surface. 2) Never apply water directly onto the electronic | components. “INT: ‘ a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leak- \ jiator front: jens — 3e problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when, ra ‘Turn on all electrical loads including the heater blower, head hts, rear window defogger, etc. and check to see if the mal- action occurs.IN-16 INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED 4, _ DIAGNOSTIC TROUBLE CODE CHART ‘| The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble- shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example '* DTC No. Indicates the diagnostic trouble code. Page or Instructions Indicates the page where the inspection procedure for each circuitis to be found, or gives instructions for checking and repairs. soe © Trouble Area Indicates the suspect area of the problem. * Detection item Indicates the system of the problem or ‘contents of the problem. DIAGNOSTIC TROUBLE CODE CHART 0 the type of instrumentor other listed in the table below. For detailé of each code, turn to the page referréd to under the “See page” for the eget oe ee De oe a 70H, “ seed (See page) oe 7 eae oma voae| MENON + Tentote ‘+ Open or st in crankshaft postion sensor arcu 7 GrankshattPosiionSensorkcut | Crankshat postion sensor onna| © (oi=12) | Mattuneton cpsamoueaGag Peon tei aia aa 13 igine circuit '¢ Engine speed sensor olf | ian" sere anal O VI ‘© Opon or shorn E-VAV for main actuator cout ! E-VRV for main actuator 15 Diesel Throtle Control Ccuit Diesel throttle position sensor ccuit s Oo (o1=32) | Mamunction ‘Diesel throtte positon sensor ONINA __ | Main actuator putt ‘© Vacuum hose disconnected or blocked Engine ECU © Engine ECUINTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED m7 SYSTEMS 5. PROBLEM SYMPTOMS TABLE * mi yuh + ‘The suspect circuits or pars for each problem sympt8m are shown inthe table below. Use ths table to trou- dieshoot the problem when a "Norma" code is displayed in the diagnostic trouble code check but the prob- 2mis still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should =e checked He SINT: fc fart When the problem is not detected by the diagnostic system even though the problem symptom is present, ‘tis considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. == [Page Incates the page where the flowchart foreach circuit . is located. a © Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem cuba eee symptom. Check in the order indicated by the numbers. in saga =H ‘ Circuit or Part Name '® Problem Symptom Indicates the circuit or part which needs to be checked. 4 PROBLEN SYMPTOMS aN ae | ¥ eympiom Soe page i 1. Stator sre Engine doesnot crank (Does not stat) ee ees IY. ECU power source circuit, Dies No initial combustion (Does not start) 2. Pre-heating system < STH 3. Compression Sate ewe 4. Engine ECU +20 1. Pre-hoating system st s 2. Star signal creuit ons ; Fe farteecinmeaicceas at Cold engine (Difleut to start) 4 Inector | - 5. Fue! fiter font Fut 8. Dioselthrota body | ~ Dea 7. Engine ECU rf IN-20 1. Staer signal rout Dens 2 imactor 5. Fuel ter 4, Diese hatte body 5. Engine ECU 1 Fuel iter 2. Diese throti bodyoe ous {& oH@2 INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEWS 6. CIRCUIT INSPECTION i aoe How to read and use each page is shown below~ ‘ Diagnostic Trouble Code No. and Detection Item © Circuit Description 2 . it ‘The major role and operation, ete. of the circuit ' and its component parts are explained. x Bre | 12 | Giarshal Poston Sopéor Cru Wane tion, CIRCUIT DESCRIPTION é Trecrarstat poston sarsorin te npn Cota Stem crassa paw ana pln oO agra mESEGEe? - ‘The TDC spratpne ha tao cur Scurerece. The TDC sara sensor gente! seal br everyenone sevton Twain ECU ate ne op Sat oot yh TDC wal, The NE eral ah #2 meth “ rmeunedin heey ping. TNE stl seae gone 2 sna cl ngne 2k The ge ECU Secs . e ‘te egne pees andcan ttpossaat supply pune, Teepe ECU see TO elena sig er pen ea ra NE sgn a rece eu cone a rene. i “rape nna co 18 | no Toc sano ongea ECU 1800 9m or 200 '* indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem, * | WIRING DIAGRAM © Wiring Diagram This shows a wiring diagram of the circuit Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circu ‘Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, 0 = Orange, W = White, GR’= Gray, P = Pink, Y= Yellow Thefts letter indicates the basic wire color andthe ‘second letter indicates the color of the stripe.ue INTRODUCTION ~ HOW TO TROUBLESHOOT ECU CONTROLLED m9 SYSTEMS, ‘¢ Indicates the position of the ignition switch during {f& check.| | # Inspection Procedure on on Use the inspection procedure to determine won Sitch LOCK (OF 3) taniton Switch ON ifthe circuit is normal or abnormal, and it Qe aa Or itis abnormal, use it to determine whether : Dy Nontion Switch ACG the problem is located in the sensors, QO lrton Sten START @m actuators, wire harness or ECU. INSPECTION PROCEDURE \: Check continu betweon terminal THW of EU connector and body round ioe PREPARATION: (@) Remove ine glove compartment (6) Disconnect the £8 connector of ECU. (CHECK: ‘Measure resistance between terminal THW of ECU connector ‘and body ground. | *™ Reslatance: 1 MA or higher | @ Indicates the place to check the voltage or resistance. ¢ Indicates the connector position to be checked, from the front or back side. ep 1B. 4 ‘Check from the connector back side. ‘Check from the connector front side. (without harness) (with hatness) In this case, care must be taken not to bend the terminals. ‘Indicates the condition of the connector of ECU during the check. a e Connector being checked is connected. Connector being checked is disconnected.IN-20 a INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED SYSTENS. HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION 1 OPEN CIRCUIT: CONNECTOR CONNECTION AND TERMINAL IN- ___ SPECTION For troubleshooting, diaghostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages. When all the component parts, wire harnesses and con- nectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is per- formed without the problem symptoms occurring, refer to step 8 to replace the ECU, even if the problemis not in the ECU. So always confirm that the problem symptoms are aceurring, oF proceed with inspection while using the symptom simulation method. ec The instructions "Check wire hamess and connector” and “Check and replace ECU’ which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. PROCEDURE * This could be due to a disconnected wire harness, faulty con- tact in the connector, and a connector terminal pulled out, etc. HINT: n 89 Itis rarely the case that a wire is broken in the middle of it, Most cases occur at the connector. In particular, care- fully check the connectors of sensors and actuators. Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a de- formation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no ab- normality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or con- wut 208° ectors. ‘ “SHORT CIRCUIT: “~~ ee | This could be due to a contact between wire hamess and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properiy.INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLE IN-21 ‘SYSTEMS. Pull Lightly Looseness of Crimping 10K 2 fa) (b) (a) (b) HI Measi CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. - | Measure the resistance between the applicable terminals of the connectors. Resistance: 1 or less | Measure the resistance while lightly shaking the wire har: ness vertically and horizontally. When tester probes are inserted into a connector, insert the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the terminals when inserting the tester probes. Has yeaee eee = LJ so scons | RESISTANCE CHECK (SHORT CIRCUIT CHECK) —] Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 M2 or higher ure the resistance while lightly shaking the wire harness vertically and horizontally. 4 (a) (b) my HINT: VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. 4 Check for rust or foreign material, etc. in the terminals of the connectors. ey Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. ' The terminals should not come out wheh piled lightly. @ NOTI Prepare a test male terminal and insert itin the female ter- minal, then pull it out CE: When testing a gold-plated female terminal, always use a gold-plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED ste vs Fig. 4 ECU OPEN sens F soe ® ft {Iz * alfa al ses : @ eau pvawig tentmot glamat bateln by zterito narit yiese srom tuo rn ne ai te 5. CONNECTOR.HANDLING ; Wheinserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminais. arts 6. CHECK OPEN CIRCUIT ‘ For the open circuit in the wire hamess in Fig. 1, perform "(a) Continuity Check” or “(b) Voltage Check" to locate the section (a)* Check the continuity. ™7 (1) Disconnect connectors "A’ and "C" and measure the resistance between them, __- In the case of Fig. 2, Between terminal 1 of connector “A* and terminal 1! of connector "G” + No continuity (open) Between terminal 2 of connector “A” and terminal 2 “sts of connector °C” + Continuity Therefore, itis found out that there is an open circuit between terminal 1 of connector "A* and terminal 1 2 of connector °C". : (2) Disconnect connector "B” and measure the resis- tance between the connectors. {In the case of Fig. 3, Between terminal 1 of connector "A" and terminal 1 of connector "B1” > Continuity Between terminal 1 of connector *B2" and terminal 1 of connector "C* > No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector °B2" and terminal 1 of connector °C", a tae n9@INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED naa SYSTEMS Yo tion by conducting a "continuity check with ground”. + roy ai i (0) Check the voltage. y In Bvircuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector “A” at the ECU 5V output terminal, terminal 1 of connector B", and terminal 1 of connector "C’, in that order. Ifthe resus are: 5V; Between Terminal 1 of connector "A" and Body Ground 5V: Between Terminal 4 of connector "B" and Body Ground OV: Between Terminal 1 of connector "C” and Body Ground ‘Then itis found out that there is an open circuit in the wire har- ness between terminal 1 of *B* and terminal 1 of °C” 7. CHECK SHORT CIRCUIT Ifthe wire harness is ground shorted as in Fig. 5, locate the sec- Check the continuity with ground. (1) Disconnect connectors °A" and °C” and measure the resistance between terminal 1 and 2 of connec- ECU tor “A” and body ground. : ground —> Continuity (short) Between terminal 2 of connector "A” and body ground —» No continuity aa Therefore, it is found out that there is a short circuit between terminal 1 of connector "A" and terminal 1 ‘of connector "C”. g In the case of Fig. 6 | + Between terminal 1 of connector “A” and bodyINTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS H en - . SAT Ty Mane 8. (2) ~ -« Disconnect connector "B” and measure the resis- tance between terminal 1 of connector "A” and body ground, and terminal 1 of connector "B2" and body ground. Between terminal 1 of connector "A and body ground ~» No continuity : Between terminal 1 of connector "B2" and body ground — Continuity (short) Therefore, itis found out that there is a short circuit between terminal 1 of connector "82" and terminal 1 of connector °C”. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a nor- ‘mal functioning one and check that the symptoms appear. anit a) Resistance: 1 Q or less (2) Measure the resistance between the ECU ground terminal and the body ground. Zi venee tot of | Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. |INTRODUCTION — TERMS ~~». TERMS ~~~ ABBREVIATIONS USED IN THIS MANUAL - ee Abbreviations Meaning aC ir Conationing ac ‘Aterating Current ACC ‘Accessory ACIS ‘Acoustic Conta Induction System 2080) ‘Automatic Cold Stan Device ALT ‘Alternator ‘Ampitior ‘Approximately ‘Automatic Transmission Transaxle) ‘Boost Altitude Compensation System Bato ‘etore Top Dead Genter Bimetalic Vacuum Switching Valve (Gicuit Breaker [Catalytic Converter for Oxidation Direct Curent Data Link Connector Diagnostic Trouble Code Electronic Control Diesal Electronic Cantal Transmission Etectronio Control Unit Electronic Driving Unit Electronie Fuel hieation Engin Exhauet Gas Recirculation Evaporative Emission Contr! Electronic Vacuum Regulating Valve Exauat Formed In Place Gasket -L Fusale Link Fr Front SND Ground) AC High Alituda Compensator G ignition nN imtogratd ignition Assemtly N Intake so le Speed Control 8 Junction Block iC Junction Connector 00, Liquid Crystal Display ED Light Emiting DiodeIN-26, Se EE EEE eee eee eee INRGOUSMGN testes ECS UE er ere eet er Steet Manitols Absolute Pressure Me Multipurpose rm Manual Transmission __} N Neutral Oas ‘Oxygen Sensor On. Overdrive os, Oversize PKB Parking Brake PS. Power Steering RAM Fandom Access Memory 8 Relay Book RH Fight-Hand Fight-Hand Drive ROM ead Only Memory Rear Starting nection Control System Speccation Special Sorvico Matorils Sst Special Senco Toole ‘STD Standard sw Switch TACH Tachomotor ToC Top Dead Center TEMP. Temperature TH Transmission TNC TOYOTA Moter Corporation Twice ‘Three-Way Catalyst i) Uedecdrive vow Vacuum Control Valve vIN Vehicle iantiication Number ‘Vacuum Switching VaWve wi Wire Harness, wio wrihout WUTC Warm Up Taree-Way Catalytic Convertor Et “Two Whee! Drive Vehicle (4x2) Wo. For Whoo! Drive Voice (4x4).. PREPARATION [CHARGING .ENGINE MECHANICAL SST (Special Service Tools) PREPARATION = _ ENGINE MECHANICAL PP | wa ‘Compression Gauge Atacnment ‘Crank shia wining gear Injection pam dive gear ORIGINS Chine Conpreaion Ok pe sa ; ia 4 (09992-00200) L Joint oF ee ~ * (09992-00211) Gauge Assy ” eee ~*~ | Pt se } oR ne | a tae GT Vas Caan Naa To HAD-SHOTE Gea Preaek OF = | wel} To ve THOT Copan age Patna ea —— > i re osm ule Bo — SS 3 eee ee savant Base Fe < > (Casi-oIaIy Farge eo : Tamara ng By | Oil pump drive gear shaft Gunratng om i Intense gor a x (09952-04010) SSCA 5 jyump-egcay | Camsbal timing puley sta “| oltpump drive gear shat + | Gruhn gee Oo oB I Injection pump dive peat {55-4010} “Gate Bo 00 Cana wr pale =) igateh Ofna ve get ((955-aianyoerBo 0 a ara tara a Cina owe geenPP-2 PREPARATION — ENGINE MECHANICAL ‘Grankshall Ol Seal Replacer ~ (09223-78010 -Qm. Injection pump dive gear oll seal TT? (09223-00010 Cover & Seal Replacer —- 09214-60010 rarkshal Puley & Gear Grerkarat pully Q JE at 2 THIG8-Gi010 Weston Needle Weorch Set, & ~Y Z (09268-64020) injection Nozzle Holder ae Injection Nozzle 62 i Retaining Nut Wrench - "09202-70020 Vale Spring Compressor Vow & 2 = como) wee \Z - 15208-48010 Corbvalon Chamber Rerover Conuston Charbor (01-1080) _Vavo Gilde Busing mover & ee F eee . (9223-46011 Grarkehat Fort 01 Sal Careshah Fora sea Replacer WW222-67OIT Connacing Rod Busing Porover A Roplacor ld i (09954-04010) Arm 25 ‘Camshaft ming pulley i < Ol pump ve gear shat CP Crank shat ing gear Injection purp eve gearPP-3 PREPARATION — ENGINE MECHANICAL Woase ION) Cawiod | D2 s (GH95E- i061) Caw os Cara ig ly Ee | Ol pump cive gear shat cA Crank shat tin gar i Injection pump drive gear Ta WROTE Puler OBL eS 1g | Goeeese 2a 2 (@9951-05010) Hanae 160 Gia eat ploy | ! [O82 06010) Revver &Repacr Conrecing rod bshiraPREPARATION —_ENGINE'WECRANICAL RECOMMENDED TOOLS ‘09040-00011 Hexagon Wrench Set z Go —+ PPS "09200-00010 Engine Adjuat Kit to (09904-00010 Expander Set = — 2 ZPP-6 EQUIPMENT Carbide cutter PREPARATION — ENGINE MECHANICAL $$ $$ SSS Caliper gauge Connecting roo algner Cylinder gauge Dial ncicator [Dye penetrant Engine tune-up testor (Gasket scraper Heater Micrometer Magnetic fnger Piston ring compressor Piston ring expander Plastgage Precision staight edge ‘Soft brush ‘Spring tostor vale soring ‘Steel square vaio spring Tachometer Thermometer Torque wrench Valve seat outer ‘V-bleck Vernier calipersPP? ERT MECHANICAL SSM (Special Service Materials) a -o¢ ?AHVO) 08826-00080 Seal Packing Back or equivalent Taisen ay vs rc) Ting gor cover ee ee i a ROWE | Camshatt ot eal retainer, — | Cr ed srt ela ug 8806-00080 Seal Pacing Banko equa Ojeda headcover (PG) Main bearing cover ls ama NOT OSEDREE (08826-00100 Seal Packing 12826, ‘THREE BOND 12828 or equivalent 16) sso : Far ci'seal etaner Wier sender gaugePP-8 22° OFREOARIATION —_ TURBOOHARGING. TURBOCHARGING SST (Special Service Tools) "09992-00242 Turbocharger Pressure Gauge a -_~ |. 09350-32014 TOYOTA Automate Transmssion. Tool Sot s ae (09351-32070) _ No? Psion Spring ComeressorPREPARATION — _TURBOCHARGING RECOMMENDED TOOLS 2 ' (09905-00013 Snap Ring PlersEQUIPMENT Daal indicator “Torque wrenchep “PREPARATION — ELECTHONICTONTROL DIESEL ELECTRONIC CONTROL DIESEL : Mus SST (Special Service Tools) D98I7-GDL] Back-up Ught Switch Too! ; oe — "09843-18020 _ Diagnosis Check Wire ar a Tae | 62PP-12 22 PREPARIETION — _ELEOTHONIC CONTROL DIESEL RECOMMENDED TOOLS ‘09082-0040 TOYOTA Elecrica Tester. a= ag = "99200-00010 Engine Adjust Kit owe -PP-13 PREPARATION — ELECTRONIC: DIESEL EQUIPMENT 7 18 mm deep sockel wrench Thermometer Torque wrench actin page LEEPER EEE EEE eee iAPP-14 none Ow" PRERARATION —_ BAGINE FUEL ENGINE FUEL «_ Hee : SST (Special Service Tools) ‘09228-64040 _ Fuel Fiter Weench (EF i Sr (09241-76022 _ Injection Pump Stand Set Zz : i : "06245-34019 Injection Pump Stand Arm (09260-4012 _ Injection Pump Too! Set SooOD (09262-54010) Dietibutor Head Plug Wronch (09262-54020) Regulator Vave Wrench (09259-$4020) Sosket 14 mm "09268-64010 Injection Nozzle Wrench Set (09268-64020) Injection Nozzle Hoider Potairing Nut Wrench ‘09950-50012 Puller C Set (09951-05010) Hanger 150 Inpction pump (09952-03010) Side AmPP-15 PREPARATION — ENGINE FUEL (09953-05020) Gorter Bol 150) injection pump | (09954-05010) Claw No.1 Injection pumpPP-16 PREPARATION —_ ENGINE FUEL RECOMMENDED TOOLS 7 Hoe Ta FR) ‘09040-00011 a | ‘Hexagon Wrench Set ah med (QsUeU- Hee) Bau" TOYOTA Electical TesterEQUIPMENT 19mm deep socket wrench Brass bush Injection nore tester PREPARATION — e ERGove FUEL Fuel temp. sensor Injection pump tester Torque wrench Water pump pers Wiooden stickPP-18 PREPARATION — COOLING ‘ ~ : cei i SST (Special Service Tools) 1 fae (09230-01010 Radiator Service Tool Set EZ 228, ~ eo GOO ~ (09731-14010 PunchPREPARATION COOLING ~~ EQUIPMENT e : Ade Heater Thermostat aciator cap tstor Thermometer Trormastat Torque wrenchPP-20 COOLANT e [tem PREPARATION —_COOUNG. Capacity 105 hers (7.1 US. ‘8.2 imp. ts) Giassincation Long Life Coolant” of valentProt PREPARATION — COOUNG “"C SSM (Special Service Materials) _ : TAD "08826-00100 Seal Packing 12828, ‘THREE BOND 12828 or equivalent (FIPS)PREPARATION — LUBRICATION LUBRICANT (a: ssia9ac} tem Capacty ‘Csiicaton Engin a [AP rorade GF-+ or OF ey 75 ors 7.9 US qs 6.2 mp. qs) ~~ | (Youmay sso use APICE oF CO) Dean an fi w/Oifiter change oters (7.6 US qs, 62 mp. as) a wo Oifiter change. 6. iters (6.8 US ats. 5.6 Imp. als)PP-26 PREPARATION — CUBRIGRTION™ SSM (Special Service Materials) : ‘Seal Packing Black or equivalent Fira) in- ipume Oilpan ‘ahosive 1344 ‘THREE SOND 1984 LOGTITE 242 oF equivalent Gi pressure sander gauge Taper sorew plug on timing gear casePREPARATION - STARTING” STARTING | SST (Special Service Tools) ‘09201-41020 _ Valve Siem Oi/Seal Replacer PP-27 AMMOD. 4 (09286-46011 Injection Pump Spline Shat Puller ‘erature rar bearing ‘09810-38140 _ Starter Magnet Swich Nut Wrench 14 "09950-00020 Bearing Remover ‘Armature fron bearingPP-28 -s RECOMMENDED TOOLS "09082-00040 TOYOTA Electrical Tesier. He be u a a Pra = STARTING ~~PREPARATION. — STARTING EQUIPMENT 7 E Dialinccator Commutator Magnetic inger ‘Steel all Plastic hammer Press Magnetic switch terminal kt Pu scale Brush song T Sendpaper Gommutator TFexque wronch Vobiock Commutation ‘Vem calipers Commutation, BushPP-30 PREPARATION — CHARGING CHARGING * SST (Special Service Tools) ‘(5285-76010 jsclon Pump Carchah Bearing Rotor roar boar cover ‘Cone Replacer = ‘28646011 njction Pump Spine Shah Rector ond rama Paler {9820-00021 Alomator Roar Boating Polo 2 ‘05820-00050 Atwater Roar Bowing Roplacor ~~ | Rolor roar boarng ‘05820-63010 Atemator Putay Sea Wrench @2 ° Sa (2950-60010 Repacer Sot ‘S88RC0C TI (09951-00260) Replacer26 Fetor ont bearing S (09951-00510) Peplacer st (09952-06010) Adaptor olor fro bearingPRI PREPARATION - CHARGING RECOMMENDED TOOLS — ~~ same THAMG: (08082-00040 TOYOTA Eictieal Tester. SBSPP-32 EQUIPMENT € “Ammeter (A) Banery spectc graviy gauge Bet tension gauge Except maintenance tree battery Folor (Sip ting), BrushSERVICE SPECIFICATIONS STANDARD BOLT... IENGINE MECHANICAL. [TURBOCHARGING ..... ELECTRONIC CONTROL DIESEL - STARTINGSERVICE SPECIFICATIONS: STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type STANDARD BOLT fi ae Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt a Weld Bott OO << Zs»SS-2 SERVICE SPEGEATIONS — SIANBARDTSOTR “7"7727 SPECIFIED TORQUE FOR STANDARD BOLTS 4 3 Spectedorqe Cress | Daneter a Hexagon head bot Hexagon Range bot Nm xgkom eb wen ohem feet 6 1 5 5 aint 8 ry Bint > e 128 125 130 8 0 as 10 wo * 1.25 26 260 Cc 18 oy wm at 2 128 ~ a 480 35 53 Ho 39 4 760 | se} 80 8 Pca “0 : “ ts o 1300 | oo 151/125) f 90 a 18 15 170 1,750 ! 127 = -~ if? 6 7 105 no ° 7% 1 3 -f-e—] vs- ]- — a — fee zo w]e ts 2 =| s | = | m4 2 125 8 17 105 | 180 a “ 145 1108 ws | a7! es} 18 230 : 168 = Ee tee ® 2 2 2 Pa 0 135 «1 4 so 2 1.25 110 4,100 80 wo | Ey 6 15 om 0 25 7 7 w 0 125 70 mo) 5H 7 mF 12 1.25 125, 1,900_* 4 140 1,450. 105, ® 12 % 200 28 22 <0 a tT 10 125 78 800 58 a8 | 30 Nt 2 125 so sso | 105 15__| 1600 0 ns @ vas) |e 0 a 7 +80 % ww 0 i @ eo | OF 7 | 980 72 2 135 15519006 175100190SERVICE =_ STORDRPEYBOCT —— HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Old Standard Hexagon Nut | Hexagon Nut“ Cold Forging Nut Culting Processed Nut OQ o \ ) () 181" Gj ame on 7 YY pian : él on mes oe ( y 7N(T) Hee J ~ ar we | 7 BN © © 40N (77) st No Mark, cantar oe | ae Seee 11N ey soe seovam ast -6r velomab reno fea bet ot © tema, lut with 1 or more marks on one side surface of the nut. “iNT: MEO ae we ot se the nut with the same number of the nut strength classification or the greater than the bolt strength clas- ‘cation number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or moress4 SERVICE SPECIFICATIONS ENGINE MECHANICAL _~ ENGINE MECHANICAL : ee SERVICE DATA -—— ae ‘Compresion STD } 3,040 kPa (31.0 kgticm®, 441 psi} or more: pressure = Minimium | 1,961 kPa (20.0 kgtlem?, 284 psi) Ditererce neween esc evinder 450 Pe (50 kglon® 71 ps ortoss ‘ave dearace ad mae [0.20-0.00 nm (0008-0012) tina [025-035 mm(or0-o914in) wo || _adst shi ticaness = i No. | 250mm (0.0984 i) No. 42 | 2.55% (0.10041) fo.08 280mm r020m) No. 43 | 2.65 mm (0.1043 in.) i: | Nott 270mm (0.1063im) No.4 | 275mm 01089) 43 ' | nate] atommoo soem) aes = at a No. 45 | 2.85 mm (0.1122 in.) “ Mow i No. 21 | 2.90 mm (0.1142 in.) t No. 4s |29smm(0.3161 in) 4B zo | No. 26 | 2.00. 0.181 9) n | No. 87 | 3.05 mm (9.1201 in.) fee beet i Not Jatomm 022010) ae No.48 {38mm 03240%n) ooo No. 36 | 3.20 mm (0.1260in.) i an ) Nowe [525mm 0.1280!) av No. 41 | 3.30 mm (0.12991in.) Wao epoed 650 —760"0m acim pond 2500-47009 Setar remeatesln ca STS 4 tensioner i Timing over” | Mergers clarence S70 [0050.1 mm (00024-00083in} 2 Maximum | 0.30 (0.0118) | eter gear inte ameter 14.0007 4.005 en (1.79291. 7338n) 1 idier gear shatt diameter | 43.955 - 43,990 mm (1.7305 ~ 1.7319 in.) . ier per of clesance 7000100070 mm 00004~00028in) = a baa Maximum | 0.20 mm (0.0079 in.) [Gear backlach | ‘STD | 0.02 ~0.15 mm (0.0008—0,0060in) re Maxirum [0:20 mm (0.0079) Oyinderneas | warpage Maximum | 0.15: (0.0088in) ave seat | tou : wrt Refacing angle Intake | 90" 45" 60" e ‘ ee — + “560° wS Contacting angle | i Jeertacing wah | snake |13~1.9mm (0050-0075in) 1 exhaust [18-22 mm (0071 ~0.087in) ‘Cylinder head bolt outer diameter STD | 11,.8—12.0 mm (0.465 - 0.472 in.) > Sy vst Ben | 1.8 (0487 in) oy Now cyndor nea gakat rness ; } tole aumoerr [60-030 mm (@0915~00354in) — — ~ Hole umbo:"” [090 1.00 mm (00954 -00398in) tote mmoer"9 | 1.00~1.40mmm (0384 —00499in) Vere gige [nite ametor inate [7 275— 7.900 mm (09140-03148 9) using tenon arityo noiteciti: Exhaust |7:360~ 7.975 mn (0.8134 -09140in)—_——: SERVICE SPECIFICATIONS — ENGINE MECHANICAL Stem Gameter intake [7975-7 960 mm (0.3140 -0.81¢6in) " $+ _ Exhaust | 7.960~7.875 mm (0.3194-09140in} Stem of dleaance «STD Intake | 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) seen exaust | 0.095 0.070 mm (0.0014 ~ 0.0028.) see axamur ttako | 0.08 mm (0.0031 in) exnaust [0.01 mm (0.0039 n) | awe face angle aoo-e “st Marginthickness =e} 87D intake | 1.5mm (0.069in) 10 exhaust | 1.7 mm (0.67 in) i “0 Minimum intake | 1.1 mm (0.048 in.) | ° 12mm (0.087 in) t Overalongth Maximum | 8.20 mm (02228) Busing inside damater osor2- 4.024 (1.9901 -f'3986in) Piston pin diametor 34.000 ~ 94.012 mm(1.3386 ~ 1.3391 in.) Piston pin aaa 7p |0.008- 0.018 mm (06003 0.0008 In} ‘Maximum | 0.03 mm (0.0012 in.) oer Big end inner diameter a (Peteere=) noe, ‘STD Mark 1 | 62.014 62.020 mm (2.4415 -2.4417in}) Sey Mark 2 | 62.020 62.026 mm (2,4417 ~ 2.4420 in.) a3 | 62.005 62.032 mm (24420-24422) ass7 senverseeonemons_—_evomevecuvon. ~~ ‘Crankshaft ‘Thrust clearanca* STD ] 0.040 — 8.240 mm (0.0016 — 0.0096 in.) oe ee Sareea Beco | STD (STD) | 2.490 — 2.480 mm (0.0957 - 0.0976 in.) | rte! ¥ in ee (us0.25) (Us 1.125) STD (STO) (US.0.25 and WIS 0.50) Maximum ‘Main joumal diameter “a onan) ns ee us02s us 080 Main bearing center wal hickxeas (Reference) STD Mark2 . Marks a y:SCMatk Maks Maks STD Markt Make Mans us02s ‘Main journal ot clearance —- Main journal taper and out-of-rourd Crank pin taper end out-of-round ‘Main bearing cap bot outer clameter 2.585 ~ 2.605 mm (0.1006 ~ 0.1028 in.) 2,498 ~ 2.543 mam (0.0861 ~ 0.1001 in) 0.096-0 054 mm (0.0014 ~ 0.0021 in.) 0.087 ~0.077 mm (0.0018 ~0.0080 in.) (0.40 me (0.0099 i.) (68.994 - 70.000 mm (2.7557 ~ 2.7559 in) 69.968 - 69.994 mm (2 7554 2.7867 in) 69,962 ~ 69.988 mm (27652 - 2.7564 in) 168.745 ~ 69.755 mm (2.7459 - 2.7469 in) 169.495 ~ 69.505 mm (2.7360 2.7364 in) 2.479 ~ 2.482 mm (0.0976 ~ 0.0977 in.) 2.482 ~2.485 mm (0.0977 ~0.0978 in.) 2.485 ~ 2.488 mm (0.0978 ~ 0.0980 in.) 2.488 — 2.491 mm (0.0980 ~ 0.0981 in.) 2.491 ~ 2.494 mm (0.0961 — 0.0982 in) ‘56.994 ~ 59.000 mm (2.3226 ~ 2.3228 in) ‘56.968 - 58.994 mm (2.9224— 2.3226 in.) ~~ —— ‘56.962 ~ 58.988 mm (2.3221 — 2.3224 in) 58.745 ~ 58.755 mm (2.3128 ~ 2.3132 in.) ‘56.495 ~ 58.505 mm (2.9028 - 2.3132 in) ‘0.06 mm (0.0024 in.) 0.002 mm (0.0008 in) _beet w= 0.002 mm (0.0008 in.) mars 19.500 ~ 14.000 mm (0.6915 — 0.5512in.) 12.60 mm (0.4961 in.) Thrust clearance SID) Maximum Not jounal i ciseranbe—P sD No.1 Bearing inside ciametor No.2 Bearing inside clametor ‘No.3 Bearing inside ciametor No.1 journal diameter ~~ ‘No.2 journal diameter ane No journal dameter_| is (0.085 —0.140 mm (0.0026 ~ 0.0055 in) 10.25 mm (0.0088 in.) 10.040 ~0.079 mm (0.0987 ~0.0876 in) (0.180 nm (0.0071 in.) 0.040 ~ 0.079 am (0.0957 ~0.0876 in) 0.190 an (0.0075 in) 0.050 ~ 0.089 mm (0.0020 = trees y——~~ 0.180 am (0.0071 in 42.000 ~ 42.020 men 1.6595 ~ 1.6543 in) 41.000 ~ 41.020 men (1.6142 — 1.6150 in) 32.000 — 31.020 mm (1.2598 ~ 1.2606 in) 4.941 — 41.980 mm (1.6512 1.6520 in) 40,931 ~ 40.950 mm (1.6115 ~ 1.6122 in} 31,941 ~31.960 mm (1.2575 ~ 1.2589 inss-8 SERVICE SPECIMCATIONS —_ENCMNENECUNAICAT“>~ TORQUE SPECIFICATION ‘Teing bet tonsioner x Timing gear case Injection pump drive gear x Injection puma idler gear x Tring gear case Timing gear cover x Timing gear case Parttightened Nm “make pipe x intake manifold 12 Injection pump x Timing gear case 2 [No.1 camshatttiming pulley x Camshaft 28 ‘No.2 camshatt timing puley x injection pump drive gear 13 {dler pulley bolt x Timing gear case 3 13, ‘Crankshaft puley x Crankshaft [Camshaft ol seal retainer x Cylinder head ‘Camshaft bearing cap x Cylinder head (Cylinder head x Cylinder book tet 2nd 3rd, Injection nozaie x Oyinder head ‘Nozzle leakage pipe x ejection nazzle ‘Water outlet x Cylinder head 16 165, 2 Intake maniford x Cylinder head 20 200 14 ‘Ol dipstick guide x Gyinder head 20 200 14 Injection pipe x Injaction nozzle 18 150 a Injection pipe x Injection pump 15 150 " Oi nozzle x Cylinder block 25 260 18 ‘Main bearing cap x Cylinder block tet 0 500 96 and] Tungo" ‘Connection rod cap x Connecting rod Ist 29 300 2 {i 2nd] tumso" ear all seal elaine x Cylinder block 13 130 a Balance shaft x Cylinder block 32 320 2 Balance shat x Oylindor block 85 Tain toh ‘ar ond plato x Cyfinder block 8, Tain. toh Flywheel x Crankshaft 145 1.480) 107 ‘Accelerator cable bracket x Oyinder head 204 15 Front engine hanger « Cylinder head a7 460 4 [LH engine mounting bracket x Cylinder block 68 693 50 [RH engine mounting bracket x Oyinder block 68 693 50.SERVICE SPROMICATIONS_— wn mr TURBOCHARGING : am ‘ anicines PELE Peete SERVICE DATA eae et * FTarbochager | Turbacharging pressure 31-67 ¥Pa (052-068 elem, 74~9.7 pa) Turbine saft ail lay q |, Maximum | 0,150 mm (0.0063 in) Turbine shat radal pay ‘asim {0.110 rim (0.0049) Aawator etvatorsvoke 1.20~ 1.70 mm (0.0872 ~ 0.06691)ss10 SERVICE SPECIFICATIONS — TURBOCHARGMG—-=- TORQUE SPECIFICATION : % an igrtoned We kgtem “Turbine init elbow x Turbocharger 1811 195 “Turbo water pipe x Turbocharger Nut 12 120 Bot 8 80 “Turbocharger x Exhaust manifold i pipe x Cylinder bok Exhaust mars x Cynder bolck (Oi pipe x Cylinder book Union bot Bot “Tuocharger stay x Turbocharger “Turbocharger stay x Gyinder block “Turbine out ebow x Turbosharger 380 28 Exhaust marital heal nsulafor x Exhaust manifold 80 ean “Turbocharger heat insulator x Turbocharger 2 20 S3in Intake pipe x take manfold 1 120, 2 Veband x Bearing hous a8 4 aint ‘Acvator x Compressor housing 1841 195, 4 Bearing housing side plale x Bearing housing 2 122, 2Timing contro! valve sS-1t SERVICE SPECIFICATIONS —_ ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL SERVICE DATA Beebe Eee (Clearance between stop screw and lever ‘Omm @in) VIA-E2 ‘omm@in) oL-€2 1,60 me (0.068 in.) " ioL-E2 ‘Throtle valve tly open ~ + ViA-E2 = vo-e2 02-88k9 23-orless Infinity 14-8540. 25-590 at 20°C (68°F) 10-140 1-20 [ressunce SS waoro@ernfi-ea Vor inte _[ Resistance 2070 60°F) Joes —a45a cenetete contol Wateronperatize | Resistance a-20'c ah | 10-2000 ‘sensor, at0°C (32°F) | 4-7hD - Fe tmperace 20°C 60"F [29k sensor, atao-c (ioa'F [09 12K0 intake air at 60°C (140°F) | 0.4—0.7 ko temperature at 80°C (176°F) sensor Turbo pressure | Power source votage we-8av sensor Engine speed Resistance at 20°C (68°F) | 205-255 2 Granignan | Resistance atcoa | 8-328 [potion sensor eee att [24270 Tnecton pump | Restance march [or -25Ka correction resistorSS-12 SERVICE spebIcATiONS — cieciRowic COWTHOT bese TORQUE SPECIFICATION 422310 .- oH Part iahtonad Nm gto tbr “Trate body «take mato 20 208 15 Witor temperature sensor x Gyinder block 25 255, 18 Fuel eenporature sensor x Fuel pump 216 220 165 ‘Crankshaft positon sersor x Gyinger look 5 a tinh 30 208, 224 First goar postion sansor switch x TransmissionSS-13 ENGINE FUEL « SERVICE DATA ‘yection pump Engine speed sensor resistance ‘Spill control valve resistance Conection resistors resistance wena 14,808 ~ 15,599 kPa (151 ~ 159 kglem, 2,148 2,261 psi) 14320~ 15,100KPa (146 - 154 kgticm?, 2,076 - 2,190 psi) 0.900 mm (0.0354 in) (950 mm 0.0376in) | — 1.000 mm (0.09940) 1.950 mm (00413) 1100 mm (00433 in) 1.180 mm (00450 in) 1.200 mm (00472.) 1.250 mm (00482 in) 4.300 mm 0512.) 1.380 mm (00531 in) 1.400 mm (00851 i.) 1.480 mm (00571 in) — 4.800 mm (0531 in) 1.880 mm (00810 in) 1.600 men (00830 in) 1.850 mn (00850 in) 1.700 mm (0.0669 in.) 1.750 mm (0689 in) 1.860 mn (0709 in) 1.880 mm (0728 ny 1.800 mm (0748 in) 1.980 mm (00768in) AUOHOT (0.925 mm (0.0364 in.) 0.975 mm (0.0384in,) 1.025 ma (0.0404 in.) 4.075 mm (0.0623) 41,425 mm (0.0443 in.) 1.475 mm (0.0469in,) 1.225 mam (0.0482 in) 41.278 mm (0.0502in,) 1.325 mm (0.0522in) 1.375 mm (0.0541 in) 1.425 rom (0.0561 in.) 1.475 mm (0.0881 in.) 1.526 mm (0.0600 in.) 1.575 mm (0.0620 in.) 1.825 mm (0.0640 in) 1.875 mm (0.0658 in.) 1.725 mm (0.0679 in) 1.778 rm (0.0699.) 1.825 mm (0.0719 in) 1.875 mo (0.0738 in) 1.925 me (0.0788 in) at 20°C (68°F) at 20°C (68°F) at 20°C (68°F) [205 - 255.0 at 20°C (68°F) 1-2 at 20°C (68°F) 0.1 ~25 ka at 20°C (68°F)ss14 __SERVICE SPECIFICATIONS —_ ENGINE TIE “7 TORQUE SPECIFICATION : Pan tightened [Nozze holder body x Nozzle holder retaining nut Injection nozzie x Cylinder head 540 40 ‘Nozze leakage pipe x injection nozzle 300 2 Injection pump clamp x Intake manifold Injection pipe x injection nozzle Injection pipe x Injection pump Acelerator cable bracket xitake pipe 20 200 5 Fuel inet hot srew x injection pur body 368 a5 2 Delivery valve node Distroutve head 8 Ditiouve head pug x Distibuive Fad 35 Fuel inlet ppe xijection pump | Cant 23 20 7 : 7 Bot 245 250 7 Feline pipe x injection pump 2 220 7 injection pump x Tiring gear case 2 210 5 Fuel tmp, sensor xDistitutve head pug (No.2) 216 20 165 [ Pump stay» injection pump 2 330 24 ump stay x Ondo look 2 210 5 Injection pump dive gear x jection pump es $50 aCOOLING © SERVICE DATA ** Thermostat ‘Valve opening tomporature =_| Valve fife (at 95°C (20°F) =adiatr cap —_| Fate valve opening pressure (STD) Rote valve opening pressure (Limit) 80 -84°C (176. 8 mm (0.31 In.) o more 74108 kPa (0.75 ~ 1.05 kllem?, 10.7 - 14.9 psi) 59KPa (0.6 kgtom®, 8.5 ps)Ss16 SERVICE SPECIFICATIONS - COOLING TORQUE SPECIFICATION 7 Partightoned Nm gfe na] (Cynder biog x Drain plug 8 #0 6210-01 Water pump x Oyinder block 13 130 8 | Aterator bracket x Gling book 2 210 6 Avernaor x Aerator bracket, ‘oak ot a 210 6 Pot bol 2 520 “6 Fan x Water pump pulley | 8s 3 | Water net xeyinde bios 13 130 9SERVICE SPECIFICATIONS — LUBRICATION — 5 LUBRICATION « SERVICE DATA »_ ' 7 ssi : oF won Oilpresuure [At cle speed (normal operating temperature) ‘At 3,000 rpm (normal operating temperature) 29 kPa (0.9 kale, 43 pai) or moro 250 ~ 600 kPa (2.56.1 kglcme, 18-42 psi) il pump @ wee Body clearance (STD) Body clearance (Maximum) _. Hip clearance (STD) Tip clearance (Maximum) ‘Side clearance (STD) ‘Side clearance (Maximum) etal au Ht 10.100 ~0.170 mm (0.0089 0.0067 in) 0.20 mm (0.0079 in) 0,050 —0.160 mm (0.0024 ~0.0069 in.) 0.21 mm (0.0088 in) 0.430 ~0.080 mm (0.0012 0.0096 in) 0.15 mm (0.0058 in)ss-18 omnes suemneneges son TORQUE SPECIFICATION Roll vave x On pump a2 225 (Oa pump x Cyinaer bloc Bot 13 130 2. Union bot 8 160 2 Injection pump x Oi pump 2 210 5 (Od stramer x Cyber block. a 20 68 in-tof (Ox pan » Cyinger lock 16 185 12 Aerator ajusting bar x Oil pump at 210 6 (Ov cocver cover x Drain plug @ 2 nibh (Or coher cover x Oil coer 16 160 2 (On cooler cover x Cylinder balck 13 130 9 Dipatick guide x intake maniold 29 300 2 (Ox nozale x Cylinder bold 26 260 18SERVICE SPECIFICATIONS STARTING e SERVICE DATA ———' — Fated voltage and output powar Noroad characteristics Brush length sr ae —- t Spring instaled ad '———————-+-- Curent sto Minimum sto Minimum =_ STARTING. 12v 22kW 120 Aorless at 11.5 4,000 7pm o¢ Moe ee 16.5 mm (0.550 in) 8.0mm (0.354 in} 26.5~323N (27-33 kyl, §9-7.3 bf) 17.5 (1.8 kg, 4.0 Ib) Commutator iamator sto | 35.0mm(1.38 in) Minimum | $4.0 mm (1.34 in) Under cut dest TO [0.7mm (0.027 in) Hy Minirnum | 0:2 man (0,008 in.) Girdle runout ‘Maximum | 0.05 mm (0.0020 in.) Magnetic switch a a Contact pate for wear Maximum | 0.9 mm (0.035 in Pre-heating | Lightighting time ‘af 20°C (68°F) | Approx. 0.5 seconds. system Glow pig Resistance, at 20°0 (68°F) | Approx. 0.72.0SERVICE SPECTRCATIONS STARTING TORQUE SPECIFICATION : Pan ngrtened ‘Sew 289 x Gyinder head ‘Sure rousing x Guich assombiy 82intoh Fasc ware x Starter housing 2 asa wie x Torna 52in Toh “erinal put Terminal 30 of starr, Teminal © of starter 2 32in toh ‘End cover x Magnetic swich housing[SERVICE SPECIMCATIONS _— CHARGING. CHARGING ® t SERVICE DATA ** ‘Specie gravity at 20°C (68°F) | 1.25 ~1.29 otage 20°C 68°F) | 125-12.9V Detection ‘New belt [8—8 mm (0.24 -0.3t in.) Used batt |= 12mm (031-047 in) nm Es New belt | 400 ~600 N (41 ~ 61 kgf) Te Used belt | 300 - 500 N (31 ~ 51 kot) Rated output 12V 70A Reference ° Tension Rotor coil resistance + at 20°C (68°F) }2.1-250 ‘Sip ing diameter eet ‘81D | 14.2mm- 14.4 mm (0.559 - 0.867 in.) T_T err | 128 (0504 rah exposed engh S10 |95~ 11.5 mm (0.374-0459in) Mini | 1.5 mm (0.059 in) Regulating votage 132—148V I regulatorSS-22 SERVICE SPECIFIERTIONS” — CPNMETNET ST on" TORQUE SPECIFICATION : ‘Atemetoe pug wt 110 1125 a Recife hoor set screw 1.96 20 F7A in-t Fear end cover x Rector ord frame 45 «6 40in bt Terminal nsulator mounting nut a a 36in-th ‘Axorar wie mounting Auk 96 100) 72 ‘Beanng retainer x Drive ond frame 26 265 220. esther holder x Drive end frame 39) 40 947 inet 1G regulator x Rectifier hotder 1.96 20 TaineNi _* DIAGNOSTICS ENGINE . DF HOW TO PROCEED WITH 1 [ROUBLESHOOTING ee Dil STOMER PROBLEM ANALYSIS CHECK D3) DIAGNOSTIC TROUBLE CODE CHART... I-12 IENGINE € - . cau TE HOW TO PROCEED WITH TROUBLESHOOTING —~ ion. Troubleshoot in accordance with the procedure on the following page. ~ Titles inside Z—7/ are titles of pages in Vehicle Brought to Workshop, this manual, with the page number indicated ub in the bottom portion. See the indicated 1 [ Customer Problem Analysis __ ¥ = pages for detailed explanations. Malfunction occurs. 5 DTC Check ] = Normal code Aas LL Maltunction code. Basic Inspection DTC Chart PDFS P.D-12 > i D]-o = Circuit Inspection i Io P.DI-19 " [Paris inspection 7] I — [ ‘Check for Intermittent Problems LZ ; ~~ [1dentitication of Problem J] Step 2, 3, §, 10, 13: Diagnostic steps permitting the 12 Jf Adjustment, Repair ff use of the hand-neld tester or eo break-out box. 13 | Confirmation Test 4Di2 = ENGINE CUSTOMER PROBLEM ANALYSIS CHECK : e . may aameagg eT yen ENGINE CONTROL SYSTEM Check Sheet | _Mspector’s comer AIT ; Model and Model Customers Name aaa “ Driver's Name Frame No, Breyece > ; : Engine Mode we License No. ‘Odometer Reading Mee ‘Engine does | C Engine does not crank No initial combustion No complete combustion Doiticutte | Engine crane siowiy a Bother cn \ g Diincorect frst idle Citdting mis abnormal — High ( rpm) ClLow( pm) [QPeortains | rough iding other & [ae oor Clveskation CDeacktre CIMutler explosion ater-fre) Surging g|_ Beery [aerccing come g Soon atter starting CD Atter accelerator pedal depressed Cengie stat | later acceteraor pedal elesed CIDumng AC operation D Shitting from N10 0 other Bales Prem Secured constant ClSometimes( times per ayimonth) (lOnce only ProblomFrequeney | Gomer - - N Weather Fine Cloudy (Rainy Snouy C1 Variovsther pe [Siew [ome cme cer Scone Lo Br Ciigheay OSvbubs —— Gionersiy — GlUpn —, Booman, & CiRough road other . BE [_Encineteme. —[Cicoie warmingup_Canerwarming up ClAny emp, Cl Omer Cistaring; Caustatterstaning( min) Ging Grecng > Engine Operation | Driving * — C\Constant speed D Acceleration DDeceleration ACawich ONOFF Ch othe \ Condition of Glow plug indicator Lamp CRemains on Sometimes lights up Does not light up Normal Mode. Normal O Maitunction code(s) (code: » Diagnostic roubie | rochans Freee ame cata , Code inspection ‘ Normal D Mattunction code(s) (code ) Lerenkmtnd (a Freezed rae cata > |1100 £ . ” ' . vit be ‘ ® BIE: Sr e o ¢ w 49 nye amlinen eye soning apr om sfi}.ebor ormorotbe: iat 2 & ab At air > evaine PRE-CHECK fe 1. DIAGNOSIS SYSTEM {a) Description + The engine ECU contains a built-in self-diagnosis system by which troubles with the engine signal net- work are detected and a check engine warning light in the combination meter lights up. 1 By analyzing various signals as shown in the later table (See page DI-12) the engine ECU detects system malfunctions relating to the sensors or ac- tuators. In the normal mode, the self-diagnosis system monitors 9 items, indicated by code No. as shown in DI-12. A check engine warning light informs the driver that a malfunction has been detected. The engine ECU stores the code(s) until itis cleared by removing the F—HTR fuse with the ignition switch off. The DTC (diagnostic trouble code) can be read by the number of blinks of the check engine warning ' light when TE1 and E1 terminals on the check con- nector are connected. When 2 or more codes are dicated, the lowest number (code) will appear first. In the test mode, 5 items, indicated by code No. as shown in DF-12 are monitored. If a malfunction is detected in any one of the systems indicated by code Nos. 22, 24, 35 and 41 the engine ECU lights the check engine warning light to warn the techni- cian that malfunction has been detected. In this case, TE2 and E1 terminals on the check connector should be connected as shown later (See page DES). In the test mode, even if the malfunction is cor- rected, the malfunction code is stored in the engine ECU memory even when the ignition switch is off. This also applies to the normal mode. The diagnos- tic mode (normal or test) and the output of the check engine warning light can be selected by connecting the TE1, TE2, and E1 terminals on the check con- nector, as shown later. ; A test mode function has been added to the func- tions of the self-diagnosis system of the normal mode for the purpose of detecting malfunctions such as poor contact, which are difficult to detect in the normal mode. This function fills up the self— diagnosis system. The test mode can be imple- mented by the technician following the appropriate procedures of check terminal connection and op- eration described later (See page DI-3).pambsiks — Be 2, DIAGNOSIS INSPECTION (Normal Mode) {a) Check the check engine warning light. (1) The check engine warning light will ight up when the ignition switch is turned ON and the engine is not running. HINT: It the check engine warning light does not light up, proceed to troubleshooting of the combination meter. (2) When the engine is started, the check engine warn- ing light should go off. If the light remains on, the diagnosis system has de- 24 tected a maffunction or abnormality in the system. i 2 (b) Check the DTC. of © (1) Turn the ignition switch ON. =~ —— il (2) Using SST, connect terminals between TE1 and £1 y of the check connector. SST 09843-18020 (8) Read the DTG from check engine warning light. As an example, the blinking patterns for codes; nor- mal, 12 and 31 are as shown on the illustration. HINT: lta DTCis not output, check the TE1 terminal circuit (See Page D3). (4) Check the details of the malfunction using the DTC o + chart on page DI-12. j2and31 (6) _Atier completing the check, disconnect the SST | from terminals TE! and £1, and turn off the display. 45.0 HINT: I the event of 2 or more malfunction codes, indication will begin from the smallest numbered code to the largest. 3. DIAGNOSIS INSPECTION (Test Mode) HINT: ‘Compared to the normal mode, the test mode has an increased sensing ability to detect malfunctions. The same diagnostic items which are detected in the normal mode can also be detected in the test mode.ae ouGNosnics _— Check the DTC... (a) > gre Fiashing ON. OFF 0.26Seconds : bler-bnert brs xod~ (ty 2) @) (a) ENGINE Initial conditions. oa \ + Battery positive voltage 11 Vor more. + Throttle valve fully closed. + NC switched OFF. ‘Tum ignition switch OFF. r hd ~ 1” Using SST, connect terminals TE2 and E1 of the check connector. SST 09843-18020 Turn the ignition switch ON. rT To confirm that the test mode is operating, check that the check engine warning light flashes when the ignition switch is turned ON. IF the check engine waming light does not flash, refer to DTC chart for the TE2 terminal circuit on page DI-53. 6) 6) a) ssT (8) ) Start the engine. Simulate the conditions of the malfunction de- scribed by the customer. After the road test, using SST, connect terminals ‘TE1 and E1 of the check connector. 09843-18020 | Read the DTC on check engine warning light in the combination meter (See page DI-3). After completing the check, disconnect the SST from terminals TE1, TE2 and E1, and turn off the display. The test mode will not start if terminals TE2 and E1 are . connected after the ignition switch is turned ON When vehicle speed is 5 knvh (3 mph) or below, DTC 42 is output, but this is not abnormal.DLS DIAGNOSTICS _—_ ENGINE: (b) Check the DTC using hand-held tester. (1) Hook up the hand-held tester to the check connec- tor. (2) Readthe DTCs by following the prompts on the tes- * ter screen. HINTS (3) Please refer to the hand-held tester operator's manual for fur- ther details. (c) Clear the DTC. . (1) After repairing the trouble areas, the DTC retained « DI = Ont .3T alsnimet tosmane Tee nr: in the engine ECU memory must be cleared out by snnoy sid removing the negative (-) terminal cable from the * o-¥ battery for 10 seconds or more with the ignition WO dotiwa te ie! switch turned OFF. HINT: /osar tf + _ In this case, other memory systems (clock, etc.) will also be cancelled out. + Ifitis necessary to work on engine components requiring removal of the negative (-) terminal cable from the bat- tery, a check must first be made to see if a DTC has been recorded. ‘i a (2) After cancellation, road test the vehicle to check ‘that a normal code is now read on the check engine warning light. a If the same DTC Apseals, it indicates that the >. trouble area has not been repaired throughly. Connector nb a) + aa (@) Engine ECU data monitor using hand-held tester (1) Hook up the hand-held tester to the check connec- tor (2) Monitor the engine ECU data by following the prompts on the tester screen. HINT: (ey f ; ft Ny + Hand-held tester has a "Snapshot" function which re- \ cords the monitored data. + Please refer to the hand-held tester operator’s manual for further details. {e) Engine ECU terminal values measurement using break- ‘out-box and hand-held tester (1) Hook up the break—out-box and hand-held tester to the vehicle. (2) Read the engine ECU inpuVoutput values by follow- ing the prompts on the tester screen. 5 HINT: —s + Hand-held tester has a "Snapshot" function. Toyota Break—Out-Box This records the measured values and is effective in the diagnosis of intermittent problems.HT DIAGNOSTICS _—_ENGINE 10 4. FAIL-SAFE CHART ' t Hf any of the following codes is recorded, the engine ECU enters fail-safe mode. « ie + Please refer to the hand-held tester/break—out-box op- % — erator’s manual for further details. DTENe Fai-Sata Operation Fai-Sate Dencivaton Conaitons 2 STOW duty is 195% Feturned 16 normal coation Engine speed 0 RPM. on 12 lye pons dsb Runes romal conn : + Spi contol vave s cut 2 + Water temp. is fixed at 60°C (140°F) eee 24 Air tomp. is fixed at 40°C (104°F) Returned to normal condition L® vgeeten voter compensentabon volumes 24a pemed io normal candtan 9 = Fue temps ted at 40°C 104"F) Feturned 10 normal condition Flowing conditon must be repeated atleast 2 nes consec- 41 he | -Aecolarator pada poston sfixod at setod vale eee ce ne ors VAs 40¥ — 2 Do not operation AG ext Fetured i normal canaiion 2 Seater OFF Returned to normal condition 5. CHECK FOR INTERMITTENT PROBLEMS | OTC)... Circuit As previously described on page DI-3, abnormality detection ability in the test mode is increased compared to that in the nor- 12 | TDC signal circuit mal mode, $0 that when intermittent problems occur in the en- ~ gine ECU signal circuits (TDC, NE, THW, THA, VRP, VRT, PIM, 13 NEsignalcircuit + ai | 1 THF, VA) shown in the table opposite, the appropriate DTC is output. 22 | Water temp. sensor circuit Accordingly, when the DTC shown in the table left (12, 13, 22, t- 24, 32, 35, 39, 41) are output during the DTC check, and in- | 24| Intakeairtemp. sensorcircuit | _ Spection of the appropriate circuits reveals no abnormality, L ~ check for intermittent problems as described below. | 32 | Correction resistors circuit By check for intermittent problems, the place where intermittent problems are occurring due to poor contacts can be isolated. 95 | Intake air pressure sensor circuil —— (1) Clear DTC (See page DI-3). ——.. _ (2) Setthe test mode. 39 | Fuel temp. sensor circuit + With the ignition switch tuthed OFF, using = - ‘SST, connect terminals TE2 and E1 of the check connector. 41 | Throttle position sensor circuit ice tt genus iene0 + Start the engine and check to see if the check engine waming light goes off. : i }DIAGNOSTICS — ENGINE" (3) Perform a Simulation Test Using the symptom simulation (See page IN~10), apply vibration and pull lightly on the wire harness, connector or terminals in the cit- 4 ‘cuit indicated by the malfunction code. gy ~+——— in this test, if the check engine warning light Tits “~ up, it indicates that the place where the wire har- ness, connector or terminals being pulled or vir 78 Biase brated has faulty contact. Check point for loose con- nections, dirt on the terminals, poor fit or other “at ——~ problems and repair as necessary HINT: ‘After cancelling out the DTC in memory and set the test mode, if the check engine warning light does not go off after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the check engine warning light still does not go off, check and replace engine ECU. 1 6. BASIC INSPECTION pee eee When the malfunction code is not confirmed in the DTC check, troubleshooting should be carried out in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following fiow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble- shoot Is battery positive voltage 11 V or more when engine is stopped? oie 3 | et Wo) ‘Charge or replace battery. 4 Ul 1 2 |Is engine cranked? is NO \\| Proceed to problem symptoms table on page 7 >| Beir oe MiDIAGNOSTICS — ENGINE _.-~ Check alr filter. . PREPARATION: Remove air filter. CHECK: Visually check that the air filter is not excessively dirty or cily. HINT: if necessary, clean the air filter with compressed air, First blow from inside thoroughly, then blow from outside of the air filter. NG | Repair or replace. ” ca OK “ a “| a iH 1 4 | Check fuel quality. Ss ‘Check that use only diesel fuel. eee a \ + Check that the fuel does not contain any impurity, —— == atad Na S| Replace fuel. > | 5 | Check engine oil (See page LU-1). «it \ 7 se Peer ea eee eee NG Repair or replace. ~~ + oe eSeee ee DHIO sures —_aeome™ 7 | Check injection timing (See page EM-8). ; fo cee: eat oK a hepaera Hetil ie ee NG_)j Adjusting injection timing. 8 | Check idle speed and maxim: jum speed (See page EM-9). ° [«] Proceed to problem symptoms table on page DI-17, NG | Repair or replace injection pump. wltienn taut sendy top 7, REFERENCE VALUE OF ENGINE ECU DATA HINT: Engine ECU data can be monitored by hand-held tester. ~ (a) Hook up the hand-held tester to the check connector. (0) Monitor engine ECU data by following the prompts on the tester screen. Please refer to the hand-held tester operator's manual for further detail (©)__ Reference Value tem Inspection Conation Feterence Valve Engine atiiagrt 46-51-08 INJECTOR Engine racing at 2.000 rp 40-45 "CK Engine racing at 3,600 pm? 33-38 CA Engine ating 9-14 708 “TH. TIMING. Engine racing at 2,000 rom 13~18°CA Engine racing et 8,000 rpm 18-23 °0A ENGINE SPO [ RPMnopt stabi (Comparcon wah tachometer) No great changes Engine at ing? 13-15V INTAKE WAN, [Engin racing af 2,000 rpm" 13-15 Engine racing at 3,000 rpm" 13-15V ‘COOLANT Engine at normal operating temp. 75. 95°6 (185 208°FY? ‘ioe tattle pasion Below 10 THROTTLE “Trotie fly apened ‘Above 25V From dosed tote postion io we open trate Gradualy nereasesDIAGNOSTICS. — ENGINE ‘During Grving (Comparison wath spesdometer) Engine icing at nexmal operating temp. VEHIGLE SPD At ecoeterator pedal fully opened 'ALIG SW LOGKON. ‘During cranking [__STASIGNAL, During cranking IDL SIGNAL Closed trotte positon AIG SIGNAL INT: I 1 ' ~": All accessories and A/C are switched OFF. “2: lf the water temperature sensor circuit is open or shorted, the engine ECU assumes an engine coolant temperature value of 80°C (176"F). GROW PLUG.DH2 DIAGNOSTICS ENGINE. DIAGNOSTIC TROUBLE CODE CHART - HINT: Parameters listed in the chart may not be exactly the same as you reading due to the type of instrument or other factors. If malfunction code is displayed during the DTC check in check (test) mode, check the circuit for the codes listed in the table below. For details of each code, turn to the page referred to under the "See page” for the respective "DTC No."in the DTC chart. =~ - : aH 7 EEE PEE teeter Seicgi oro Ne. 2 Detecton item Treble rea Wearing ont ee (Normatece’ | MOTO aeovs | TestMece) | is eet Open o sor crankhat poston sensor creat 12 | Engine Speed Senter Creat | cransnat poston sensor owon | 0 (01-19) | Matunction (TOC or Gt Giruit) Engine ECU ‘Open oF shor in engine spood sensor circuit Engine speed sensor Engine ECU Open or shor in timing contol valve cuit Sanna tang. | "722! ter (Cog9ing) 14 | Tmng Control Systom Mallar | ry (Freezing Ain) ONNA ° pee eee “lnjecton pump (Internal pressure and timing contol valve) «Engine ECU. we water Tonp. Senso Gran wy | "OPE" OT AIA water tomp, Sonor crt 13 | Engine Spesd Sensor Circult (01-21) | Mattunction (NE Circuit) ‘ah tomy sor conor | 0 (0-25) | function venga ecu 24 | mat tere Sore cio | Oe Srnpme cron | o vane (0-28) taltunction Engine EOU. - Ope fh on pnp oven eo 22 | ren Pump conan oy (eetin “Recon pump carcino crron | 0 econ “enero od + Open or short in turbo pressure sensor circuit os [rutwressuesereercrau_|Totn ser soe (I-33) | Malfunction ‘+ Vacuum hose disconnected or blocked 7 “Ereeo Ip sos onan | Opn oto ana seco ty (A “Poses sear own | o ~Open rsh Twos pon sar a cl [Maiegotonsoneciet | rene enon sora — | ow | o “pe 20 ~ Opn she open ser ; 12 | voice preasomor sina |"etonspetsnea (O41) | Circuit Matfunction +Combination meter OFFOFF o “eames - “3 ++Open or short in starter circuit slat Son cicuvatincen |‘opmerstotmionenanta osanaroayciet | oFrcer | ons) 3 “ermme eo ~ pao stn par nae a cong [age PoonCstas | oa pomton th orrorr | x Engine ECU csOH13 DIAGNOSTICS _—_ ENGINE "ON" displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. "OFF" indicates that the check engine warning light does not light up during malfunction diagnosis, even if a malfunction is detected. °N.A." indicates that the item is not included in mal- function diagnosis. ' pee *2:4O"in the memory column iMdicates hat a DTC is recorded in thé énglié ECU theméty wndnla mattUne- tion occurs. Accordingly, output of diagnostic results in the normal or test mode is done with the ignition switch turned ON, "xX" indicates that a DTC is not recorded in the ECU memory even if a malfunction ocours.OM4 DIAGNOSTICS —_ ENGINE PARTS LOCATION : fe Starter Relay (Marking: ST RLY) ECD Main Relay ‘Glow Plug Relay (Marking: ECD) (Marking: SUB GLW RLY) ‘Turbo Pressure’ Sensor Water Temperature’ Sensor Engine Speed Sensor No.2 Injection Pump. ResistorDe15 DIAGNOSTcs — ENGINE: TERMINALS OF ECU : Engine ECUTerminals ® - parte reler taper y PPTs prety mopperperstetett eels eh shia [iepepapepa apops) Paap apa apa ‘Symbos (erminalNa) | _ Wiring Color Coneion STD votage W) BF 66-1) —61 (Eta) y-5___ [Aways 3-4 486 (E612) £1 4-14) PABA [1 ewten ON on16 VC (5-1) -E2(E5-9) B-GA_[iGowtch On 45-55 Accelerator pda ily eased 03-08 VA 5-11) £2 (€5-9) B1-or ree . Accoleratr pedal uly opened 29-49 Accelerator paca tly cased 14 (01 (€5-12)-£2 5-9) BA-GR iy ‘Aeoslorater pedal uly opened o-9 Aoply vacuum 40 KPa(300 mmig, 11 Bina) 13-18 PIM (€5-2)~ £2 (65-9) By-oR fe Apply vacuum 89 Pa (1,000 mmig, 39.4 in Hg) 3238 | THAGS9)-€2(E58) | _PL=G-R | Wing. Airntke emp. 0°C (°F) 10 60°C (40°F) 05-94 TH (E54) —€2 5-8) P=GA | ding, Engine coon emp, 60°C (140° to 120°C (48°F) 02-10 THF (€5-5) = £2 (65-8) 1G-6-G-A_ [1G swicnOn at engine cos) os-ae | STA(E6-11)-E1 E14) Vor=R [Cranking 6.0 oro Pause generation Tos (Ees)-T0c-e-1 | _ A-G | ting ence Pause genorton NE (4-4) NE- (64-17) wee [ring : Pestana Pulse generation SPO (€6-8)~ EI (4-14) -0-BR |G switch ON, Rotate cving whee! slowly lon mors iG witch ON 14 Toviesr2)-eor erin) | Ga-en fo Pulse generation @ (See pag2 01-22) VSV OFF (ing) 9-14 ‘mt (64-10) E01 G1 or-aA hain Jebel VSV ON (ater IG ewich OFF for2 sea) 0-8 SV OFF (ing) a1 He (E4-9)—E01 Eas oy-8R Seer eenie 'VSV ON (ter ewich OFF fo 2 00) 0-8 MREL(ES-3)-E1(6@14) | Lo-pn fOSuehON sa14 TBF [ator iG ewtch OFF tor socor mare O15 GSW EST) —E1(Ee14) | BW-BA [IG owich ON a4 TAG (66-18) E1 (64-14) 3-8 |iding Pulse generation Chock engine warring W(E6-5)-E1 4-14) POR caromarig tet gheup Except check engine warning ight Fgh up ‘Geo neater ight ight GND 5-7)-01 (6419) | RW-aR ee Eroept ow inca ght igh up an14 SVR ESE ERI | C-OR [iG owen on 0-18 [rierecereciy, | -erootlesones 7MDHE DIAGNOSTICS _— ENGINE SAEL EE) —eOv eet | GABA [Cranking oi IG awieh ON oat SPV TERA) - E01 (€4-13) BBR ng ; lee generation - {See page DI-60) re aeeeray Loon [astiiptoni tease [su At other sh postionn st ostion 0-3 ‘ab (E6-6) 62 (5-9) Ga-GA_[IGomenon 02-45 VAT (€6-14)-E2 (E58) LB-G-R_[1Gsmenow 02-45PROBLEM SYMPTOMS TABLE CANOES ENGINE ‘t 7 DLT When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. [ aaa Suspect Aa ‘Seepage 1. Stator one Does not erank (Diticltto start) 2. Starter relay a 1. STAssignal cout Ha3) 2. Injection nozzie Fus Cold engine (Dificut to stat) 3. Fuolfitor Fut 4. Engine ECU I-20 5. Injection pump FUIS Hot engine (Dficultto start) l | ‘Soon after stating (Engine stall thers (Engine sta Engine ECU power source circuit, Spill contrat vaive ralay ecu Engine ECU eee Injection puma 1. STA signal orcut Deas) 2. Injection nozzio Fus 3. Fuel itor Fu 4. Throttle Booy £03 5. Engine ECU N20 8. Ijection pump FUs5 1. Fuel iter Fus 2, Engine ECU power source circuit DHag 8. Engine ECU In-20 4. Injection pump =) Leo N20 1. Fuel iter Fut eon fst (Poor ising) 2. Engine ECU 20 3. licction pump FUAS a aaa 1. STAS@nalcreut ——— (| - one 2, Throttle poston sensor 0-8 “heron ide poe Per 1 Vl reds be 1 | 5. Engine ECU 7 IN-20 Injection pump FUAS + 1. jection nozzle | 2. Comoression ~ - ose 3. Throttle body, ————— 7 omc erie sens Por ia “8 Petia) a om 16, Engine ECU . oe 7 7. Iriection pump ee 8. Water tmp. sensor 1. iction nozze 2. Fusl line (Airbed) 2 8. Pre-heating contol circuit sre = 4. Compression a eM ough iing (Poor iting) 5. Throttle postion sensor 0-3 6. Crankshatt postion sensor £08 7. Valve clearance EM 8. Engine ECU N20 6 Injection pump FU5DH DIAGNOSTICS —_ ENGINE 1. Injoation nozzle * rus sate eit 2. Engine ECU power source circuit D9 8. Compression eM2 ‘Hunting at hot engine (Poor ing) << 6” 4. Foal ine (Ai beed) es 5. Valve clearance EM 6. Engine ECU n-20 7. Injection pump Fuss 1. Inston nozzle res 2. Engine ECU power source crcut Die 3. Pro-heating control circuit sT-2 4. Compression EM2 Hunting at cold engine (Poor iting) Sear eh o : c 6. Vawe clearance EMA Wa Engine ECU a IN-20 2._inecton pump FUAS 1. trecton nozzle Fue 2, Fuel iter ~- Fut Hesitation Poor acceleration (Poor driveability) 3. Compression Me S| Engine £OU In-20 27] 5 tection pump FUAS 1. Inection nozzie| Fue ! fuori enuoe wea! 12 Engine ECU hala a Knocking (Poor erveabity) 3. Crankshat posiston onsor 0-21 sagan 4. Spill cortl valve ccut Di-60 5._Waler temp. sensor E05 1. Injection nozzle rus i \ 2, Engine ECU N20 ht | Injection pump FU4S, Black smoke (Poor criveabiliy) 4. Spill control valve cecut 60 1 | 8. Terote body £08 6. Throtle poston sensor 0-3 7, Intake air temp. sensor ED-17 1. Pro-heating contol crout ST-2 é 2. injection nozzio rs 3. Fue ter rus 4. Engine ECU n-20 bocbasetectaiiaanLa 5. Injection pump Fuss J. Cranks tiat post 8888 ED-21 7. Theta body 50-3 {8 Wiator temp sensor FOS 1. Injcton nozzle Fue 2. Engne ECU we IN-20 sean wa orca one ne =|. Thattie postion sensor £03D9 DIAGNOSTICS_—_ENGINE CIRCUIT INSPECTION 5 a OTC 12 Engine S| Sensor Circuit Malfunction (TDC or G1 Circuit) ts | CIRCUIT DESCRIPTION o The crankshaft position sensor in the Engine Control System corns signal plate and a pickup ool for TOC signal. The TDC signal plate has 1 tooth on its outer circumference. The TDC signal sensor generates 1 signal for every engine revolution. The engine ECU detects the top dead center by the TDC signals. The engine speed sensor in the Engine Control System contains signal plate and a pickup coil for NE signal: The NE signal plate has 52 teeth and is mounted in the injection pump. The NE signal sensor generates 52 signals of engine 2 revolutions. The engine ECU detects the engine speed and cam lift position of the injec- tion pump. The engine ECU uses TDC signal and NE signals for injection timing control. And NE signal is used for injoc- ‘ion volume control, also. DTC No, DIC Code Detecting Condition “Trouble Area ] * Open or short in crankshaft postion sensor circuit 12 | NoTDC signal to engine ECU during cranking + Crankshaft postion sped sensor = Engine ECU WIRING DIAGRAM . Engine ECU Crankshatt Position Sensor Engine Speed Sensor {Built into Injection Pump)DI-20 Diagnostics — ERE INSPECTION PROCEDURE 1 OK 2 pnimit ne TOC and NE Signal Waveforms Reference: INSPECTION USING OSCILLOSCOPE at During cranking or idling, check the waveform between termi- nals TDC+ and TDC-~ of the engine ECU connector. 2V/DIV. HINT: Check resistance of crankshaft position sensor (See page ED-20). — The correct wavaforms are as shown. a ne) Replace crankshaft position sensor. vig BM one tenpie 28a US" crankshatt position sensor (See page IN-20). Check for open and short in harness and connector between engine ECU and oe ee wo) cc ga SeEEEEESESEESEES, ol Repair or replace harness or connector. + wna 3 ora? nnittand Hadasinesh) Inspect crankshaft position sensor installation. s | > Tighten crankshatt position sensor. . waulh 3 Check and replace engine ECU (See page IN20).DIAGNOSTICS — ENGINE —""7 DTC 13 Engine Speed Sensor Circuit Malfunction Circuit) oH CIRCUIT DESCRIPTION «> Refer to DTC 12 on page D9. DTCNo. DIC Detecting Condition Trouble Area ‘Open or shor in engine spaced censor circuit ‘Engine speed sensor Engine ECU WIRING DIAGRAM Refer to DTC 12 on page DI-19.— zz ou —L__} INSPECTION PROCEDURE 1 | Check resistance of engine speed sensor (See page ED-20). a HH NG | Replace injection pump assembly. e r : OK \ SeHeoee a eee eee eee a ae ee 2. | Check for open and short in harness and connector between engine ECU and engine speed sensor (See page IN-20). — =| nc\)frearrmnseehamesorcomct, Repair or replace harness or connector. ok = iH feet ” Inspect engine speed sensor installation. > Tighten engine speed sensor. eae ok Check and replace engine ECU (See page IN-20). No NE signal to engine EQU for 0.5 see. or more at 680 7pm or 13DINGNOSTICS — ENGINE: DTC 14 Timing Control System Malfunction CIRCUIT DESCRIPTION The engine ECU control the injection timing by actuating the timing control valve. The timing control vaive is mounted on the injection pump and delay one by duty control of pump internal fuel pressure. The engine ECU detects the injection advance angle by TOC and NE signals. DTG No. [DTC Detecting Consition “Trouble Area ‘Open or shor in timing contol valve circuit ____ [After engine warm up and curing, actual injection timing is | «Fuel iter (Clogging) Pepi 14” | diferent from target value of engine ECU calculatedfor several | «Fuel (Freezing, Air in) see. “Injection pump (internal pressure and timing contr} valve) WIRING DIAGRAM SARIS Enns Engine ECU RL RL os fon Tiinmals 1 ot of ECD Relay ‘Timing Control Valve: (See page D439) J oe fel eee reso 7 i INSPECTION PROCEDURE nesDe23 biAGNosTICs — ENGINE 2 | Check voltage between terminal TCV of engine ECU connector and body ground. PREPARATION: (@)__ Remove the glove compartment (See page ED-25). (b) Disconnect the £4 connector from the engine ECU. (©) Turn the ignition switch ON. CHECK: Measure the voltage between terminal TCV of the engine ECU connector and body ground, OK: Voltage: 9-14 V on) Go to step 3. ‘Check for open or short in harness and connector between timing control valve and engine ECU, and timing control valve and ECD main relay (Marking: ECD) (See page IN-20). TCV Signal Waveform 10 w/ DIV. Check voltage between terminal TCV of engine ECU connector and body ground. 10 msec. Division (Idling) __ yaaa PREPARATION: {@) Remove the glove compartment (See page ED-25). (b) _ Turn the ignition switch ON. CHECK: a= ‘Measure the voltage between terminal TCV of the engine ECU connector and body ground. Ok: ~~ Voltage: 9-14V Sa 7 Reference: INSPECTION USING OSCILLoscope ~=—! During idling, check the waveform between terminals TCV and E1 of the engine ECU connector. HINT: The correct waveformis as shown, ws NG \\| Check and replace engine ECU (See page IN-20),DL24 DIAGROSTICS_— ENGINE ~*~ Check fuel filter clogging, fuel freezing and fuel air in. Check (See a6 > Replace fuel filter. \d replace injection pum raetg. "ieetion pump oiDIAGNOSTICS _—_ ENGINE i. oo DTC 22 Water Temp. Sensor Circuit Malfunction wok CIRCUIT DESCRIPTION { ct i “The water temperature sensor senses the coolant temperature. i 5 A thermistor built into the sensor changes the resistance value t according to the coolant temperature. The lower the coolant le temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor re- sistance value (See Fig. 1). ‘The water temperature sensor is connected to the engine ECU (See below). The 5 V power source voltage in the engine ECU is applied to the water temperature sensor from the terminal THW via a resistor R. That's, resistor A and the water tempera- ture sensor are connected in series. When the resistance value of the water temperature sensor changes in accordance with changes in the coolant temperature, the potential at the termi- nal THW also changes. Based on this signal, the engine ECU increases the fuel injection volume to improve driveability dur- ing cold engine operation. su 6yer (4) (82) (68) (104) (140) (176) (212) i Pee Temperature "C ("F) 7 @s-03 noe var ) Fig.1 Resistance ka. DIG No. DTC Detecting Condtion Trouble Area Open or short in water temp. sensor cuit Water temp. censor + Engine ECU, Resistance value of water temo, sensor circuit goes out of a compensentation value for 0.5 sec. or more HINT: ‘Atter confirming DTC'22, use the hand-held tester to confirm the water temperature from the CURRENT DATA. var Het Temperature Sayed SOC OA Ta" BAF ormore TWatoncton pen crcut Shor creutDE26 WIRING DIAGRAM eee a Water Temp. Sensor INSPECTION PROCEDURE WF oe HINT: If DTCs 22, 24 and 39 are output simultaneously, E2 (sensor ground) may be open. Check voltage between terminals THW and E2 of engine ECU connector. PREPARATION: (@) Remove the glove compartment (See page ED-25). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals THW and E2 of the en- ine ECU connector. s OK: Wator Temp. °CCF) age 20 (68) (Engine is cool) 27-29V. 20 (176) (Engine is hot) 16V | OK \\| Check tor intermittent problems | (See page DI-3). Se cA) y Check water temperature sensor (See page ED-15). NG | Replace water temperature sensor.DH27 DIAGNOSTICS —_ ENGINE water temperature sensor (See page IN-20). [ =) Repair or replace harness or connector. ’! ‘ison us o 0K 1 1 8 In 1 od) S u 7; 3 | Check for open and short in harness and connector between engine ECU and | AtDiL28 DTC | 24 fa Intake Air Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION .. _ Fig.1 Resistance kQ ~2 0 20 40 6 60 100 (4) 52 68 104 140 176 212 aalZan | The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor builtin the sensor changes the resistance value according to the in- take air temperature. The lower the intake air temperature, the greater the thermistor, the lower the thermistor resistance value (Gee Fig. 1). The intake air temperature sensor is Connected td fhé engine ECU. The 5 V power source voltage in the engine ECU is ap- plied to the intake air temperature sensor from terminal THA via a resistor R. That is, resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes, based on this sig- ral, the engine ECU increases the fuel injection volume to im- prove drivability during cold engine operation. Temp. °C (°F) ore Te Suan Gn Tis seq) [Peseen esis tmp seer ccatvain | -Obn eto ae aonn sree sonst compensentaion valve lr 05eae-ormoe [Tanta HINT: I After confirming DTC 24, use the hand-held tester to confirm the intake air temperature from the CURRENT DATA. Tarp spayed Taio 40°C 40°F) Open circuit Tare maneme Storia